Filterless and bagless vacuum cleaner incorporating a sling shot separator

ABSTRACT

A vacuum cleaner includes a body having a nozzle assembly including a suction inlet and a control assembly. A suction generator and a dirt collection vessel are both carried on the body. The dirt collection vessel includes a fine particle separator unit having at least one sling shot separator. Each sling shot separator includes a flow channel having an inlet, a debris discharge port and a clean air discharge port. The flow channel has a radius of curvature of between about 12 mm and about 25 mm and extends in an arc of less than 360° from the inlet to the clean air discharge outlet.

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates generally to the floor care equipment field and, more particularly, to a highly efficient and effective vacuum cleaner incorporating a fine particle separator unit having at least one sling shot separator.

BACKGROUND OF THE INVENTION

Cyclonic vacuum cleaners have long been known in the art. Such vacuum cleaners remove dirt and debris from the air stream by means of vortex separation. Specifically, a high speed rotating air flow is established within a cylindrical chamber often referred to as a cyclone. Air flows in a spiral pattern before exiting the cyclone through an axially directed outlet. Rotational effects, centrifugal force and gravity all function to separate dirt and debris from the air stream. Specifically, larger particles in the rotating stream have too much inertia to follow the tight curve of the stream. Such particles strike the outer wall of the cyclone falling to the bottom of the cyclone where they are collected and removed. Relatively clean air is then drawn through the axially directed outlet.

The present invention relates to a vacuum cleaner incorporating a new and improved fine particle separator unit that relies upon one or more sling shot separators extending through an arc of less than 360° in order to clean the air stream.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, a vacuum cleaner is provided comprising a body including (a) a nozzle assembly including a suction inlet and (b) a control assembly. Both a suction generator and a dirt collection vessel are carried on the body. The dirt collection vessel includes a fine particle separator unit having at least one sling shot separator. Each sling shot separator includes a flow channel having an inlet, a debris discharge port and a clean air discharge port. The flow channel also has a radius of curvature of between about 12 mm and about 25 mm and extends in an arc of less than 360° from the inlet to the clean discharge outlet. In one possible embodiment the flow channel extends in an arc of less than 270°. In yet another possible embodiment the flow channel extends in an arc of about 180°. In yet another possible embodiment the flow channel has a radius of curvature of between about 12 mm and about 16 mm.

The fine particle separator unit typically includes between six and sixteen sling shot separators. The fine particle separator unit is substantially disc shaped and has an overall diameter to height ratio of between about 25 and about 1 or between about 12 and about 1.

More specifically describing the invention, the flow channel has a cross sectional area of between about 78 mm² and about 314 mm². The inlet has a cross sectional area of between about 78 mm² and about 314 mm². The debris discharge port has a cross sectional area of between about 36 mm² and about 154 mm². The clean air discharge port has a cross sectional area of between about 36 mm² and about 154 mm².

Still more specifically, the flow channel has a cross sectional area of between about 78 mm² and about 176 mm². The inlet has a cross sectional area of between about 78 mm² and about 176 mm². The debris discharge port has a cross sectional area of between about 36 mm² and about 85 mm². The clean air discharge port has a cross sectional area of between about 36 mm² and about 85 mm².

In accordance with yet another aspect of the present invention a vacuum cleaner comprises a body including (a) a nozzle assembly including a suction inlet and (b) a control assembly. A suction generator and a dirt collection vessel are both carried on the body. The dirt collection vessel includes (a) a primary separator including a cylindrical dirt cup, a tangentially directed inlet and an axially directed outlet and (b) a fine particle separator unit downstream from the primary separator. The fine particle separator unit includes at least one sling shot separator. Each of the sling shot separators includes a flow channel having an inlet, a debris discharge port and a clean air discharge port. Further, the flow channel has a radius of curvature of between about 12 mm and about 25 mm and extends in an arc of less than 360° from the inlet to the clean air discharge outlet.

In yet another embodiment the vacuum cleaner further includes a second line particle separator unit with at least one sling shot, separator downstream, from the first fine particle separator unit.

In the following description there is shown and described several different embodiments of the invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects ail without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings:

FIG. 1 a is a partially broken-away, front perspective view of an upright vacuum cleaner constructed in accordance with the teachings of the present invention;

FIG. 1 b is a rear perspective view;

FIG. 2 is a detailed cross sectional view of the dirt collection vessel including the fine particle separator unit and illustrating the air stream flow through the primary separator into the fine particle separator unit;

FIG. 3 is another detailed cross sectional view illustrating the air stream flow as it is discharged from the fine particle separator unit;

FIG. 4 is a detailed, transverse cross sectional view through the fine particle separator unit clearly illustrating the flow channel, inlet, debris discharge port and clean air discharge of each sling shot separator provided in the unit; and

FIG. 5 is a schematical view of an alternative embodiment of the dirt collection vessel of the present invention incorporating two fine particle separator units in series.

Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Reference is now made to FIG. 1 illustrating an upright vacuum cleaner 10 of the present invention. While an upright vacuum cleaner 10 is illustrated, it should be appreciated that the present invention is not limited to upright vacuum cleaners but instead covers any type of vacuum cleaner incorporating the novel dirt collection vessel 12 of the present invention. This includes but is not limited to, canister vacuum cleaners.

The vacuum cleaner 10 includes a body, generally designated by reference numeral 14. The body 14 includes a nozzle assembly 16 and a control or handle assembly 18. As is known in the art, the control assembly 18 is pivotally connected to the nozzle assembly 16 to aid the operator in manipulating the vacuum cleaner 10 back and forth across the floor. Wheels 20 (only two illustrated) carried on the body 14 allow the vacuum cleaner 10 to be moved smoothly across the floor. As illustrated, the nozzle assembly 16 is equipped with a suction inlet 22. A rotary agitator 24, including bristle tufts, wipers or cleaning ribs 26, is mounted on the nozzle assembly 16 and extends across the suction inlet 22. The rotary agitator 24 rotates relative to the nozzle assembly 16 in a manner well known in the art.

The control assembly 18 carries a suction generator 28 (i.e. a fan and motor assembly) and the dirt collection vessel 12. The details of the dirt collection vessel 12 will be described in greater detail below. The control assembly 18 also includes a control stalk 30 and an actuator switch (not shown) for turning the vacuum cleaner 10 on and off. The vacuum cleaner 10 may be powered by electricity from an electrical wall outlet through a power cord (not shown) and/or by means of an onboard battery.

In operation, the rotary agitator 24 quietly and efficiently brushes dirt and debris from the nap of an underlying carpet. That loosened dirt and debris is first drawn into the suction inlet 22 before being delivered to the dirt collection vessel 12 by means of the suction generator 28. Dirt and debris is trapped in the dirt collection vessel 12. Clean air is drawn from the dirt collection vessel 12 over the motor of the suction generator 28 to provide cooling before being exhausted back into the environment through the exhaust vent or port 34.

As best illustrated in FIGS. 2 and 3, the dirt collection vessel 12 includes a primary cyclone 40 having a first, stepped cylindrical side wall 42 and a bottom wall 44. In one possible embodiment the bottom wall 44 is connected by means of a hinge 46 and latch mechanism (not shown) to the side wall 42. Thus, the bottom wall 44 may be pivoted open to allow emptying of the primary dirt collection chamber 50 provided inside the side wall 42. A seal 52 is provided between the bottom wall 44 and the side wall 42.

The primary cyclone 40 also includes a first tangentially directed inlet 54. A shroud 56, concentrically received within the side wall 42, includes an upper lip 58, a lower lip 60 and a side wall 62 including a series of perforations or openings. Upper lip 58 defines an axially directed outlet of the primary cyclone 40.

The dirt collection vessel 12 also includes an inner wall 64 that is concentrically received within the shroud 56 and the first cylindrical sidewall 42. The lower end of the inner wall 64 is connected to the bottom wall or door 44 by a connector 66. The upper end of the inner wall 64 incorporates a collector 68. The collector 68 forms a base for supporting a fine particle separator unit 70.

As best illustrated in FIG. 4, the fine particle separator unit 70 is disc shaped and has an overall diameter to height ratio of between about 12 to about 1. The fine particle separator unit 70 includes at least one sling shot separator 72 and most typically includes between six and sixteen sling shot separators. Ten sling shot separators 72 are illustrated in FIG. 4. More specifically, the sling shot separators 72 are radially arrayed around the separator unit 70 outside a central opening 74.

Each sling shot separator 72 includes a flow channel 76 having an inlet 78, a debris discharge port 80 and a clean air discharge port 82. The flow channel 76 has a radius of curvature of between about 12 mm and about 25 mm in one possible embodiment and between about 12 mm and about 16 mm in another possible embodiment. Further, the flow channel extends in an arc of less than 360° from the inlet 78 to the clean air discharge outlet 82. In another possible embodiment the flow channel 76 extends in an arc of less than 270°. In yet another possible embodiment the flow channel 76 extends in an arc of about 180°.

Further describing the invention, the flow channel 76 has a cross sectional area of between about 78 mm² and about 314 mm², the inlet 78 has a cross sectional area of between about 78 mm² and about 314 mm², the debris discharge port 80 has a cross sectional area of between about 36 mm² and about 154 mm² and the clean air discharge port 82 has a cross sectional area of between about 36 mm² and about 154 mm².

In yet another possible embodiment the flow channel 76 has a cross sectional area of between about 78 mm² and about 176 mm², the inlet 78 has a cross sectional area of between about 78 mm² and about 176 mm², the debris discharge port 80 has a cross sectional area of between about 36 mm² and about 85 mm² and the clean air discharge port 82 has a cross sectional area of between about 36 mm² and about 85 mm².

Reference is now made to FIGS. 2 and 3 illustrating the air stream flow through the dirt collection vessel 12. During vacuum cleaner 10 operation, the rotary agitator 24 brushes dirt and debris from the nap of an underlying carpet. That loosened dirt and debris is drawn into the suction inlet 22 by means of the suction generator 28. The air stream, including the entrained dirt and debris is then delivered to the dirt collection vessel 12 through the tangentially directed inlet 54 (see FIG. 2). The air stream then moves cyclonically around the primary dirt collection chamber 50 (note action arrows A). The rotating air stream generates centrifugal forces that function with gravity to separate dirt and debris from the air stream. Specifically, larger particles in the rotating air stream have too much inertia to follow the curve of the stream. Such particles strike the cylindrical side wall 42 falling under the force of gravity to the bottom of the primary dirt collection chamber 50 where they collect. The step 55 in the sidewall 42 helps maintain dirt and debris in the lower portion of the chamber 50. The relatively clean air is then drawn through the apertures in the side walls 62 of the shroud 56 and the axially directed outlet formed by the upper lip 58 (see action arrow B).

Next the air stream is drawn through the passageway 57 into the inlets 78 of the sling shot separators 72 (see action arrows C). The inlets 78 function to feed the air stream into the individual flow channels 76. As the air stream flows around the arcuate pathway of the flow channels 76 (see FIG. 4, action arrow D), any remaining fine particles and debris are forced toward the outer portion of the flow channel 76. More specifically, the radius of curvature of each flow channel 76 is sufficiently small to produce angular acceleration that increases the rotational kinetic energy of the fine particles in the air stream so that the particles are efficiently moved to the outside surface of the arcuate air path. As a consequence, the fine particles remaining in the air stream are swept toward and into the debris discharge ports 80 (see action arrow E) while relatively clean air along the inside portion of the air path defined by the flow channels 76 is swept toward the clean air discharge ports 82 (see action arrow F). Dirt and debris passing through the debris discharge port 80 is exhausted into the central opening 74. There the dirt and debris then falls under the force of gravity into the collector 68 which serves to deliver the dirt and debris into the secondary dirt collection chamber 84 provided in the inner wall 64 (see FIG. 3, action arrows G). Simultaneously, the clean air passing through the clean air discharge ports 82 is delivered into the discharge manifold 86 in the lid 88 of the dirt collection vessel 12 (see action arrows H). Next the air stream travels through a discharge outlet 90 in the lid 88 and passes through a conduit (not shown) to the suction generator 28. The air stream then passes over the motor of the suction generator 28 to cool the motor before being exhausted through the discharge outlet 34.

In yet another embodiment of the present invention schematically illustrated in FIG. 5, the dirt collection vessel 12 includes a second fine particle separator unit 100 downstream from the first fine particle separator unit 70. The second fine particle separator unit 100 may be substantially structurally identical to the first fine particle separator unit 70 described above. Significantly, the clean air discharge ports 82 of the first fine particle separator unit 70 are provided in fluid communication with the inlets 78 of the flow channels 76 provided in the second fine particle separator 100. Operating together the first and second fine particle separator units 70, 100 provide two stage fine particle separation. More specifically, the air stream passes through the sling shot separators 72 of the two units in series with any fine particles passing through the debris discharge ports 80 in the two units. That debris then passes through the central openings 74 and the collector 68 before being collected in the secondary dirt collection chamber 84. The clean air exiting the clean air discharge ports 82 of the second fine particle separator unit 100 passes into the discharge manifold 86 before passing through the discharge outlet 90 on its way to the suction generator 28.

In summary, numerous benefits result from employing the concepts of the present invention. The sling shot separators 72 of the fine particle separator units 70, 100 provide a highly efficient and very compact structure for removing fine particles from an air stream as it travels through a vacuum cleaner 10. As a consequence, a dirt collection vessel 12 of a given size may include larger capacity dirt collection chambers 50, 84 allowing for longer operation before the dirt collection vessel fills and requires emptying. Alternatively, the dirt collection vessel 12 may be made smaller to allow for a more compact and lighter weight, vacuum cleaner 10 that may be more easily manipulated by the operator without sacrificing cleaning efficiency.

The foregoing description of the preferred embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way. 

1. A vacuum cleaner, comprising: a body including (a) a nozzle assembly including a suction inlet and (b) a control assembly; a suction generator carried on said body; and a dirt collection vessel carried on said body; said dirt collection vessel including a fine particle separator unit having at least one sling shot separator, said at least one sling shot separator including a flow channel having an inlet, a debris discharge port and a clean air discharge port, said flow channel having a radius of curvature of between about 12 mm and about 25 mm and extending in an arc of less than 360° from said inlet to said clean air discharge outlet.
 2. The vacuum cleaner of claim 1, wherein said flow channel extends in an arc of less than 270°.
 3. The vacuum cleaner of claim 1, wherein said flow channel extends in an arc of about 180°.
 4. The vacuum cleaner of claim 1, wherein said flow channel has a radius of curvature of between about 12 mm and about 16 mm.
 5. The vacuum cleaner of claim 1, wherein said fine particle separator unit includes between 6 and 16 sling shot separators.
 6. The vacuum cleaner of claim 5, wherein said fine particle separator unit is substantially disc shaped and has an overall diameter to height ratio of between about 12 and about
 1. 7. The vacuum cleaner of claim 1, wherein (a) said flow channel has a cross sectional area of between about 78 mm² and about 314 mm², (b) said inlet has a cross sectional area of between about 78 mm² and about 314 mm², (c) said debris discharge port has a cross sectional area of between about 36 mm² and about 154 mm² and (d) said clean air discharge port has a cross sectional area of between about 36 mm² and about 154 mm².
 8. The vacuum cleaner of claim 1, wherein (a) said flow channel has a cross sectional area of between about 78 mm² and about 176 mm², (b) said inlet has a cross sectional area of between about 78 mm² and about 176 mm², (c) said debris discharge port has a cross sectional area of between about 36 mm² and about 85 mm² and (d) said clean air discharge port has a cross sectional area of between about 36 mm² and about 85 mm².
 9. A vacuum cleaner comprising: a body including (a) a nozzle assembly including a suction inlet and (b) a control assembly; a suction generator carried on said body; and a dirt collection vessel carried on said body; said dirt collection vessel including (a) a primary separator including a cylindrical dirt cup, a tangentially directed inlet and an axially directed outlet and (b) a fine particle separator unit downstream from said primary separator, said fine particle separator unit including at least one sling shot separator, said at least one sling shot separator including a flow channel having an inlet, a debris discharge port and a clean air discharge port, said flow channel having a radius of curvature of between about 12 mm and about 25 mm and extending in an arc of less than 360° from said inlet to said clean air discharge outlet.
 10. The vacuum cleaner of claim 9, wherein said flow channel extends in an arc of less than 270°.
 11. The vacuum cleaner of claim 9, wherein said flow channel extends in an arc of about 180°.
 12. The vacuum cleaner of claim 9, wherein said flow channel has a radius of curvature of between about 12 mm and about 16 mm.
 13. The vacuum cleaner of claim 9, wherein said fine particle separator unit includes between 6 and 16 sling shot separators.
 14. The vacuum cleaner of claim 13, wherein said fine particle separator unit is substantially disc shaped and has an overall diameter to height ratio of between, about 12 and about
 1. 15. The vacuum cleaner of claim 9, wherein (a) said flow channel has a cross sectional area of between about 78 mm² and about 314 mm², (b) said inlet has a cross sectional area of between about 78 mm² and about 314 mm², (c) said debris discharge port has a cross sectional area of between about 36 mm² and about 154 mm² and (d) said clean air discharge port has a cross sectional area of between about 36 mm² and about 154 mm².
 16. The vacuum cleaner of claim 9, wherein (a) said flow channel has a cross sectional area of between about 78 mm² and about 176 mm², (b) said inlet has a cross sectional area of between about 78 mm² and about 176 mm², (c) said debris discharge port has a cross sectional area of between about 36 mm² and about 85 mm² and (d) said clean air discharge port has a cross sectional area of between about 36 mm² and about 85 mm².
 17. The vacuum cleaner of claim 9 further including a second fine particle separator unit downstream from said fine particle separator unit.
 18. The vacuum cleaner of claim 17, wherein said second fine particle separator unit includes at least one sling shot separator having one second flow channel having a second inlet, a second debris discharge port and a second clean air discharge port, said second flow channel extends in an arc of less than 270°.
 19. The vacuum cleaner of claim 17, wherein said second fine particle separator unit includes at least one sling shot separator having one second flow channel having a second inlet, a second debris discharge port and a second clean air discharge port, said second flow channel extends in an arc of about 180°.
 20. The vacuum cleaner of claim 18, wherein said second flow channel has a radius of curvature of between about 12 mm and about 16 mm.
 21. The vacuum cleaner of claim 17, wherein said second fine particle separator unit includes between 6 and 16 sling shot separators.
 22. The vacuum cleaner of claim 21, wherein said second fine particle separator unit is substantially disc shaped and has an overall diameter to height ratio of between about 12 and about
 1. 23. The vacuum cleaner of claim 18, wherein (a) said second flow channel has a cross sectional area of between about 78 mm² and about 314 mm², (b) said second inlet has a cross sectional area of between about 78 mm² and about 314 mm², (c) said second debris discharge port has a cross sectional area of between about 36 mm² and about 154 mm² and (d) said second clean air discharge port has a cross sectional area of between about 36 mm² and about 154 mm².
 24. The vacuum cleaner of claim 18, wherein (a) said second flow channel has a cross sectional area of between about 78 mm² and about 176 mm², (b) said second inlet has a cross sectional area of between about 78 mm² and about 176 mm², (c) said second debris discharge port has a cross sectional area of between about 36 mm² and about 85 mm² and (d) said second clean air discharge port has a cross sectional area of between about 36 mm² and about 85 mm². 